Greenlee LPK1230, LPK1240, LPK1240K, LPK1550, LPK1550FT User manual

Greenlee
Brand
Greenlee
Model
LPK1230, LPK1240, LPK1240K, LPK1550, LPK1550FT
Category
Power tools
Type
User manual

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INSTRUCTION MANUAL
Hydraulic
Crimping Tools
99932245 REV 7 © 2019 Greenlee Tools, Inc. 2/19
Read and understand all of the instructions and
safety information in this manual before operating
or servicing this tool.
Register this product at www.greenlee.com
LPK1230 LPK1240
LPK1240K LPK1550 LPK1550FT
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
2
LPK1550FT 15-ton Hydraulic Crimping Tool
50.8 mm (2.00") Jaw Opening
Ilsco ILD-P Dies
Burndy™ “P” Dies
Industry Standard 12-ton Type “U” Dies
(requires 52060610 “U” Die Adapter Kit)*
* The dies and die holder kits are purchased separately.
These tools are protected by U.S. Patent No. 5,778,755.
Safety
Safety is essential in the use and maintenance of
Greenlee tools and equipment. This instruction manual
and any markings on the tool provide information for
avoiding hazards and unsafe practices related to the
use of this tool. Observe all of the safety information
provided.
Purpose of this Manual
This manual is intended to familiarize all personnel with
the safe operation and maintenance procedures for the
following Greenlee tools:
LPK1230 (49340) Serial Code FYB
LPK1240 (49345) Serial Code FYD
LPK1240K (49350) Serial Code FYE
LPK1550 (49355) Serial Code FYF
LPK1550FT (00490) Serial Code GPC
Keep this manual available to all personnel.
Replacement manuals are available upon request
at no charge at www.greenlee.com.
Other Publications
Tool Owners/Users
SAE Standard J1273 (Hose and Hose Assemblies):
Publication 99930323
Greenlee Authorized Service Centers
Service Manuals:
LPK1230: Publication 99932253
LPK1240: Publication 99932261
LPK1240K: Publication 99932270
LPK1550: Publication 99932288
LPK1550FT: Publication 52059642
All specications are nominal and may change as design
improvements occur. Greenlee Tools, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.
Blackburn is a registered trademark of Thomas and Betts Corporation.
Burndy is a trademark of Framatome Connectors International.
Table of Contents
Description .................................................................... 2
Safety ............................................................................ 2
Purpose of this Manual ................................................. 2
Other Publications ......................................................... 2
Important Safety Information ..................................... 3-5
Identication .................................................................. 6
Specications ............................................................. 7-8
Tool Setup ..................................................................... 9
Hoses and Fittings ...................................................... 10
Hose Connections ....................................................... 10
Typical Setup ............................................................... 10
Operation ..................................................................... 11
LPK1550 Die Installation ........................................ 12-14
LPK1550FT Die Installation ......................................... 15
Maintenance ................................................................ 16
Periodic Pressure Relief Valve Check.......................... 16
Troubleshooting ........................................................... 17
Illustrations and Parts Lists .................................... 18-27
Description
Greenlee Hydraulic Crimping Tools are intended to
crimp connectors onto electrical cable. All of these
crimping tools can be adapted for use with either
open-center or closed-center hydraulic systems.
The crimping tools and removable dies* they accept are
as follows:
LPK1230, LPK1240, and LPK1240K
12-ton Hydraulic Crimping Tools
30 mm (1.18") Jaw Opening
LPK1230: Industry Standard 12-ton Type “U” Dies
42 mm (1.65") Jaw Opening
LPK1240: Industry Standard 12-ton Type “U” Dies
LPK1240K: Kearney PH2 and WH2 Dies
LPK1550 15-ton Hydraulic Crimping Tool
Jaw Opening is dependent on Die Set
Kearney PH14 Dies
Kearney PH2 Dies (requires 48824 Die Holder Kit)*
Thomas & Betts TBM 15 Dies
(requires 48788 Die Holder Kit)*
Burndy™ Y46 Type “P” Dies
(requires 48820 Die Holder Kit)*
Industry Standard 12-ton Type “U” Dies
(requires 48802 Die Holder Kit)*
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
3
KEEP THIS MANUAL
IMPORTANT SAFETY INFORMATION
SAFETY
ALERT
SYMBOL
This symbol is used to call your attention to hazards
or unsafe practices which could result in an injury or
property damage. The signal word, dened below,
indicates the severity of the hazard. The message
after the signal word provides information for pre-
venting or avoiding the hazard.
Immediate hazards which, if not avoided, WILL result
in severe injury or death.
Hazards which, if not avoided, COULD result in
severe injury or death.
Hazards or unsafe practices which, if not avoided,
MAY result in injury or property damage.
Read and understand all of the
instructions and safety information
in this manual before operating or
servicing this tool.
Failure to observe this warning
could result in severe injury or death.
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certied
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are
injured by escaping oil, seek medical
attention immediately.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Wear hearing protection when using
this tool.
Long-term exposure to high noise
levels could result in hearing
damage.
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
4
The hydraulic cylinder may be hot
during and after operation. Hot sur-
faces can cause serious burns.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning
could result in severe injury or death.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
• The relief valve sounds to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe these warnings could result in
severe injury or death.
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 34.1 l/min (9 gpm).
• Pressure relief setting: 172 bar (2500 psi).
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Do not disconnect tool, hoses, or ttings while the
power source is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Do not reverse hydraulic ow. Operation with
hydraulic ow reversed can cause tool malfunction.
Connect the pressure (supply) hose and tank (return)
hose to the proper tool ports.
Failure to observe this warning could result in severe
injury or death.
Do not change accessories, inspect, adjust, or
clean tool when it is connected to a power source.
Accidental start-up can result in serious injury.
Failure to observe this warning could result in severe
injury or death.
• Inspect tool before use. Replace any worn or
damaged parts. A damaged or improperly assem-
bled tool can break and strike nearby personnel.
• Inspect the hydraulic hoses and couplings every
operating day. Repair or replace if leakage, crack-
ing, wear, or damage is evident. Damaged hoses
or couplings can fail, resulting in injury or property
damage.
• Use this tool for manufacturer’s intended use only.
Use other than that which is described in this
manual could result in injury or property damage.
Failure to observe these warnings could result in
severe injury or death.
IMPORTANT SAFETY INFORMATION
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
5
IMPORTANT SAFETY INFORMATION
• Do not operate the tool without a set of dies in
place. Damage to the ram or crimping tool head
can result.
• Maintain proper footing to prevent loss of balance
in case of unexpected movement of the crimping
tool.
• Do not perform any service or maintenance other
than as described in this manual. Injury or
damage to the tool may result.
Failure to observe these precautions may result in
injury and property damage.
Hydraulic oil can cause skin irritation.
• Handle the tool and hoses with care to prevent
skin contact with hydraulic oil.
• In case of accidental skin contact with hydraulic
oil, wash the affected area immediately to remove
the oil.
Failure to observe these precautions may result in
injury.
Procedure for connecting or disconnecting hydraulic
hoses, ttings, or components:
1. Move the ow lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Follow the sequence under “Hose Connections”
to prevent pressure buildup. In case some
pressure has built up, loosen hoses, ttings, or
components slowly.
Emergency stop procedure:
1. Release the trigger.
2. Shut off the hydraulic power source.
Note: Keep all decals clean and legible, and replace
when necessary.
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
6
Identification
1. Crimping Head
2. Crimping Head Release Mechanism
3. Dies (not included)
4. Handle
5. Return Port (farther from trigger)
6. Pressure Port (closer to trigger)
7. Trigger Strap
8. Trigger
9. Cylinder
10. Pull Pin (LPK1550FT only)
LPK1230 LPK1240
LPK1240K LPK1550
1
2
4
5
6
8
9
7
1
2
4
5
6
8
9
7
1
2
4
5
6
8
9
7
2
4
5
6
8
9
7
1
LPK1550FT
1
8
9
10
4
5
6
2
7
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
7
Specifications
Crimping Tool—All Models
Type of Hydraulic System: Open-center
or closed-center
Hydraulic Ports:
Pressure (supply): 3/4-16 UNF SAE O-ring Boss
Tank (return): 3/4-16 UNF SAE O-ring Boss
Noise Levels
L
WA
(Sound Power Level): 55.5 dB
L
pCpeak
(Peak Emission Sound Pressure Level):
68.8 dB
Vibration: 3.15 ms
2
LPK1230 Crimping Tool
Stroke (with dies): 30 mm (1.19")
Crimping Force @ 103 bar (1500 psi):
106.7 kN (24,000 lb)
Mass/Weight: 8.4 kg (18.5 lb)
Length: 490 mm (19.3")
Width: 140 mm (5.5")
LPK1240 Crimping Tool
Stroke (with dies): 42 mm (1.65")
Crimping Force @ 103 bar (1500 psi):
106.7 kN (24,000 lb)
Mass/Weight: 8.9 kg (19.7 lb)
Length: 516 mm (20.3")
Width: 140 mm (5.5")
LPK1240K Crimping Tool
Stroke (with dies): 41 mm (1.62")
Crimping Force @ 103 bar (1500 psi):
106.7 kN (24,000 lb)
Mass/Weight: 8.8 kg (19.5 lb)
Length: 516 mm (20.3")
Width: 140 mm (5.5")
LPK1550 Crimping Tool
Stroke (without dies): 58 mm (2.28")
Crimping Force @ 103 bar (1500 psi):
133 kN (30,000 lb)
Mass/Weight: 13.0 kg (28.6 lb)
Length: 605 mm (23.8")
Width: 165 mm (6.5")
LPK1550FT Crimping Tool
Stroke (without dies): 50.8 mm (2.00")
Crimping Force @ 103 bar (1500 psi):
133 kN (30,000 lb)
Mass/Weight: 11.1 kg (24.5 lb)
Length: 602 mm (23.7")
Width: 165 mm (6.5")
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
8
Specifications (cont’d)
Hydraulic Power Source
Do not exceed the following hydraulic power source
maximums:
• Hydraulic ow: 34.1 l/min (9 gpm).
• Pressure relief setting: 172 bar (2500 psi).
• Back pressure: 13.8 bar (200 psi)
Failure to observe this warning could result in severe
injury or death.
Type of Hydraulic System: Open-center
or closed-center
Flow:
Minimum: 11.4 l/min (3 gpm)
Recommended: 22.7 l/min (6 gpm)
Maximum: 34.1 l/min (9 gpm)
Pressure Relief Setting:
Minimum: 103 bar (1500 psi)
Maximum: 172 bar (2500 psi)
Filtration: 10 micron (nominal)
Back Pressure (maximum*): 13.8 bar (200 psi)
* 13.8 bar (200 psi) is the maximum agreed standard back pressure
for the HTMA (Hydraulic Tool Manufacturers Association).
Greenlee tools will operate satisfactorily at this standard.
1. Maximum hydraulic uid temperature must not
exceed 60 °C (140 °F). A sufcient oil cooling
capacity is needed to limit the hydraulic uid
temperature.
2. Hydraulic ow must not exceed 34.1 l/min (9 gpm).
Install a ow meter in the return line to measure the
rate of hydraulic ow before using the tool.
3. Pressure relief valve setting must not exceed
172 bar (2500 psi) at your tool’s maximum ow.
Locate the pressure relief valve in the supply circuit
to limit excessive hydraulic pressure to the tool.
Hydraulic Schematic
FILTER
(10 MICRON)
COOLER
RELIEF
VALVE
172 bar
(2500 psi)
CONTROL
VALVE
FLOW METER
T
P
TOOL
RESERVOIR
PUMP
POWER SOURCE
Recommended Hydraulic Fluids
Use any nondetergent, petroleum-based hydraulic
uid which meets the following specications or HTMA
specications.
S.U.S. @:
38 °C (100 °F): 140 to 225
99 °C (210 °F): 40 minimum
Flash Point: 170 °C (340 °F) minimum
Pour Point: –34 °C (–30 °F) minimum
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
9
Tool Setup
This tool can be used on either open-center or
closed-center hydraulic systems.
Open-Center Setting
1. With the ram retracted, disconnect the crimping tool
from the hydraulic power source.
2. Loosen the two seal nuts. Back each seal nut out to
the end of the screw.
3. Turn the screws clockwise—evenly, alternating
every one to two turns—until they contact the piston
and feel snug.
4. Back the screws out—evenly, alternating every one
to two turns—exactly four complete turns.
5. Hold the screws in place with an Allen wrench and
tighten the seal nuts against the cover. Torque the
seal nuts to 6.78 newton-meters (5 ft-lb).
Adjusting
Screw
Seal Nut
Closed-Center Setting
1. Disconnect the crimping tool from the hydraulic
power source.
2. Loosen the two seal nuts.
3. Turn the screws counterclockwise—evenly,
alternating every one to two turns—until they
contact the stops.
4. Hold the screws in place with an Allen wrench and
tighten the seal nuts against the cover. Torque the
seal nuts to 6.78 newton-meters (5 ft-lb).
Adjusting
Screw
Seal Nut
Installing Dies
1. Clean the die seat area.
2. Install the proper size and type of crimping dies.
Note: For LPK1550 and LPK1550FT only, refer
to “LPK1550 Die Installation” or “LPK1550FT Die
Installation.”
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
10
Hoses and Fittings
Installation and Maintenance
Refer to publication 99930323, SAE J1273
(Hose and Hose Assemblies).
Replacement
Refer to a Greenlee catalog or publication 99910322,
Low Pressure Quick Couplers, Adapters and Hoses.
Do not disconnect tool, hoses, or ttings while the
power source is running or if the hydraulic uid is
hot. Hot hydraulic uid can cause serious burns.
Hose Connections
Tool Port Identification
Three methods are used to identify the pressure and
return ports of Greenlee tools. Match the markings on
your tool to this table.
Pressure Port Return Port
P T
or
In Out
or
3/4–16 O-ring Boss
Connecting Hoses
1. Move the ow control lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Connect the return hose to the return port on the
power source, and then to the return port on the
tool.
4. Connect the pressure hose to the pressure port on
the tool, and then to the pressure port on the power
source.
Disconnecting Hoses
1. Move the ow control lever on the hydraulic power
source to the OFF position.
2. Stop the hydraulic power source.
3. Disconnect the pressure hose from the power
source, and then from the tool.
4. Disconnect the return hose from the tool, and then
from the power source.
Typical Setup
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
11
Operation
Electric shock hazard:
This tool is not insulated. When
using this unit near energized
electrical lines, use only certied
non-conductive hoses and proper
personal protective equipment.
Failure to observe this warning
could result in severe injury or death.
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are
injured by escaping oil, seek medical
attention immediately.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Keep hands away from the crimping
tool head when crimping.
Failure to observe this warning
could result in severe injury or death.
An incomplete crimp can cause a re.
• Use proper die, connector, and cable combina-
tions. Improper combinations can result in an
incomplete crimp.
• The relief valve sounds to indicate a completed
crimp. If you do not hear the sound of the relief
valve, the crimp is not complete.
Failure to observe these warnings could result in
severe injury or death.
1. Refer to the connector manufacturer’s instructions
for cable preparation and the crimping procedure.
2. Center the connector between the dies or nibs.
3. Press the trigger to advance the dies or nibs.
• Press the trigger down completely for fast
advance.
• Press the trigger down partially for slow advance.
4. Continue crimping until the pressure relief valve
activates.
Note: Pressure relief is indicated by a change in the
sound from the crimping tool and a sudden stiffen-
ing of the hydraulic hoses.
5. After achieving pressure relief, release the trigger.
The dies retract.
6. Complete the number of crimps specied by the
connector manufacturer.
7. When the tool is not in use, stop the power source
to reduce heat and wear on tool components.
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
12
LPK1550 Die Installation
Kearney PH14 Dies
Note: No die holder assemblies are needed.
Dies fit directly into tool.
1. Select proper die set for tting to be crimped.
Note: Do not use non-butting dies (crimps con-
trolled by tonnage) in this tool, as damage could
occur to connectors and/or conductors.
2. Install upper die in hole in top of “C” head. Detent
screw will snap into groove of die.
3. Install lower die in hole in end of piston. Detent
screw will snap into groove of die.
Kearney PH2 Dies and 48824 Die Holder Kit
1. Install 48823G PH2 die spacer assembly into hole
in top of “C” head. Detent screw will snap into
groove of die spacer.
2. Install upper 48825 die holder assembly into hole in
die spacer assembly. Lock in place with die spacer
retaining screw.
3. Install lower 48825 die holder assembly in hole in
end of piston. Detent screw will snap into groove
of die holder.
4. Select proper die set for tting to be crimped.
Note: Do not use non-butting dies (crimps con-
trolled by tonnage) in this tool, as damage could
occur to connectors and/or conductors.
5. Slide die into place in top die holder tight against
shoulder. Detent screw snaps into groove of die.
Lock in place with top die retaining cap screw.
Repeat for other die.
Detent Screws
Detent Screw retains
Bottom Die Holder
Detent Screw retains
Die Spacer
Top Die Holder
Retaining Screw
Top Die
Retaining Screw
Bottom Die
Retaining Screw
48825 PH2
Die Holder
Assemblies
48823G PH2
Die Spacer
Assembly
48824 Die Holder Kit for PH2 Dies
contains one 48823G and two 48825 Die Holders
PH14 Dies
Detent Screw retains
Bottom Die
Detent Screw retains
Top Die
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
13
LPK1550 Die Installation (cont’d)
Thomas & Betts TBM 15 Dies
and 48788 Die Holder Kit
1. Install the upper 48789 die holder assembly in hole
in top of “C” head. Detent screw will snap into
groove of die holder.
2. Install lower 48789 die holder assembly in hole in
end of piston. Detent screw will snap into groove
of die holder.
3. Select proper die set for the connector to be
crimped.
4. Slide top die into place in die holder while depress-
ing die retainer button. Release die button while it
snaps into place, locking die into position. Repeat
for other die.
48789 TBM 15
Die Holder Assemblies
Bottom Die Retaining
Mechanism
Top Die Retaining
Mechanism
Detent Screw retains
Top Die Holder
Detent Screw retains
Bottom Die Holder
48788 Die Holder Kit
contains two 48789 Die Holders
Burndy Y46 Type P Dies and 48820 Die Holder Kit
1. Install the upper 48822 die holder assembly in hole
in top of “C” head. Detent screw will snap into
groove of die holder.
2. Install lower 48821 die holder assembly in hole in
end of piston. Detent screw will snap into groove
of die holder.
3. Select proper die set for the connector to be
crimped.
4. Slide top die into place in die holder while simulta-
neously squeezing both retainer buttons. Release
buttons and allow them to snap into place. Repeat
for other die.
Detent Screw retains
Bottom Die Holder
Detent Screw retains
Top Die Holder
Top Die Retaining
Mechanism
48822 Y46
Die Holder Assembly
Bottom Die Retaining
Mechanism
48820 Die Holder Kit contains one 48822
Upper Die Holder and one 48821 Lower Die Holder
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
14
LPK1550 Die Installation (cont’d)
Industry Standard 12-ton Type “U” Dies
and 48802 Die Holder Kit
1. Install the upper 48803G die holder assembly in
hole in top of “C” head. Detent screw will snap into
groove of die holder.
2. Install lower 48803G die holder assembly in hole in
end of piston. Detent screw will snap into groove
of die holder.
3. Select proper die set for the connector to be
crimped.
4. Slide die into place in die holder while depressing
die retainer button. Release die button while it
snaps into place, locking die into position. Repeat
for other die.
Detent Screw retains
Bottom Die Holder
Detent Screw retains
Top Die Holder
48803G 12-ton
Type U Die Holder Assemblies
Die Retaining Mechanisms
48802 Die Holder Kit for 12-ton Type “U” Dies
contains two 48803G Die Holders
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
15
LPK1550FT Die Installation
Procedure for Using “P” Style Dies
1. No die holder assemblies are needed. Dies t
directly into tool.
2. Select proper die set for connector to be crimped.
3. Slide top die into place in die holder while simulta-
neously squeezing retainer button. Release button
and allow die to snap into place. Repeat operation
for other die entry.
Procedure for Using 12-ton “U” Style Dies
withUA15T Die Adapter Set
1. Slide a die adapter assembly into the ip-top head
while depressing the die retainer button. Release
the retainer button while the adapter snaps into
place. The die adapter should be locked in position.
2. Repeat Step 1 to install the other die adapter into
the ram end.
3. Select the proper “U” die set for the connector to be
crimped.
4. Slide the “U” die into the die adapter while depress-
ing the die retainer button. Release the die button
while it snaps into place, locking the die into
position.
5. Repeat Step 4 with other “U” die.
Top Die Retaining
Mechanism
Bottom Die Retaining
Mechanism
Die Retainer
Buttons
Die Retainer
Buttons
12-ton “U” Die Adapter Set
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
16
Maintenance
Skin injection hazard:
• Do not use hands to check for
leaks.
• Do not hold hose or couplers
while the hydraulic system is
pressurized.
• Depressurize the hydraulic system
before servicing.
Oil under pressure easily punc-
tures skin, causing serious injury,
gangrene, or death. If you are
injured by escaping oil, seek medical
attention immediately.
Wear eye protection when operating
or servicing this tool.
Failure to wear eye protection could
result in serious eye injury from
ying debris or hydraulic oil.
Notes:
(1) Keep all decals clean and legible. Replace decals
when necessary.
(2) When disposing of any components (hydraulic hoses,
hydraulic fluid, worn parts, etc.), do so in accordance
with federal, state and local laws or ordinances.
Daily
1. Thoroughly wipe all tool surfaces clean. Remove any
oxide inhibitor, connector contact compound, and
grit from the die seat areas, dies and die holders.
2. Inspect the hydraulic hoses and ttings for signs of
leaks, cracks, wear or damage. Replace if necessary.
3. Install dust caps over the hydraulic ports when the
tool is disconnected.
Monthly
1. Perform a thorough inspection of the hydraulic hoses
and ttings as described in publication 99930323,
SAE J1273 (Hose and Hose Assemblies).
2. Apply a light oil to all moving parts.
Quarterly or Every 500 Crimps
Perform the “Periodic Pressure Relief Valve Check.”
Annually
If required by your organization’s regulations, send the
tool to a Greenlee Authorized Service Center.
Periodic Pressure Relief Valve Check
Test the crimping tool periodically to ensure that the
pressure relief valve activates at the proper pressure.
1. Test the crimping tool with either a Greenlee load
cell or with an in-line pressure gauge.
• Purchase a Greenlee Load Cell, catalog number
35887. Refer to the instructions supplied with the
load cell.
• Install an in-line pressure gauge on the input side
of the tool. With dies in place, perform a test
crimp.
2. Pressure relief should occur at 103 to 107 bar
(1500 to 1550 psi).
3. If pressure relief occurs outside of the speci-
ed range, send the crimping tool to a Greenlee
Authorized Service Center.
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
17
Problem Probable Cause Probable Remedy
Tool does not operate. Improper power source. Verify that the power source meets the
specications. Refer to the “Specications”
section.
Hydraulic uid level low. Check the uid level. Check system for leaks.
Incorrect hydraulic uid viscosity. Use hydraulic uid with the correct viscosity.
Refer to the “Specications” section.
Tool operates slowly or
erratically.
Hydraulic uid cold. Allow uid to warm to the operating
temperature. Actuate the tool intermittently to
reduce the warming time.
Power source not adjusted correctly. Refer to the power source operator’s manual.
Set the ow and pressure to correspond with
the tool.
Hydraulic uid level low. Check the uid level. Check system for leaks.
Air in the hydraulic system. Refer to the power source manufacturer’s
instructions for removing air from the system.
Incorrect hydraulic uid viscosity. Use hydraulic uid with the correct viscosity.
Refer to the “Specications” section.
Tool feels hot. Hydraulic uid level low. Check the uid level. Check for leaks.
Incorrect hydraulic uid viscosity. Use hydraulic uid with the correct viscosity.
Refer to the “Specications” section.
Hydraulic uid dirty. Refer to the power source owner’s manual for
procedure to replace hydraulic oil and lter.
Tool operates backward. Hose connections at tool are
reversed.
Depressurize the hydraulic system. Switch the
hose connections.
Crimping tool does not
achieve pressure relief.
Improper power source. Verify that the power source meets the
specications. Refer to the “Specications”
section.
Dies do not retract. Dies caught on crimped connector. Twist crimping tool from side to side to free it
from the connector.
Excessive system back pressure. Troubleshoot the hydraulic system.
Troubleshooting
Before troubleshooting, determine whether the problem
is in the tool, the hoses, or the power source. Substitute
a tool, hoses, or power source known to be in good
working order to eliminate the item that is not operating.
If the problem is in the tool, see the troubleshoot-
ing table in this manual. If the problem is in the power
source, see the troubleshooting section of the power
source instruction manual.
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
18
Illustration—
LPK1230
2
70
64
63
65
8
3
4
9
53
11
12
57
13
51
27
40
39
37
38
22
45
10
5
6
17
73
18
7
24
25
25
30
32
34
31
33
28
26
35
36
40
47
46
50
48
49
55
72
54
20
14
29
44
16
15
19
15
16
44
24
23
21
41, 42, 43
56
67
61
69
68
66
62
62
1
52
58
60
59
Hydraulic Crimping Tools
Greenlee Tools, inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
19
Parts List—LPK1230
UPC No.
Key 78-3310- Part No. Description Qty
1 05372 50053728 C-head unit (includes items
8, 61–65, 69, 70) ...................................1
2 49342 50493426 Ram.......................................................1
3* Washer, ram ..........................................1
4* Wiper, ram .............................................1
5 Screw, cap, 1/4–20 x .87",
socket head ..........................................1
6 49344 52026772 Cylinder (includes items
53–56, 71, 72) .......................................1
7 48733 50487337 Piston .................................................... 1
8* Pin, groove (6 mm x 12 mm) ................. 2
9* Backup ring, 1.375 x 1.62 x .121" ........1
10* O-ring, 1.375 x 1.62 x .125"..................1
11 43546 50435469 Spool, shuttle ........................................ 2
12 43547 50435477 Washer, shuttle .....................................2
13 Screw, cap, #6–32 x .375",
at head socket ....................................2
14 48727 50487272 Ring, shuttle stop ..................................1
15 48728 50487280 Screw, stop ring .................................... 2
16* Retaining ring ........................................ 2
17* Backup ring, 4.312 x 4.500 x .125 ........ 1
18* Seal unit ................................................1
19* O-ring ....................................................1
20 45659 50456598 Cover, cylinder ......................................1
21 48737 50487370 Shim, handle ............................... 6 (max)
22 43554 50435540 Tube ......................................................1
23 42685 50426851 Carrier, seal ...........................................1
24* O-ring, .375 x .500 x .062"–70 ..............2
25* Backup ring, .382 x .486 x .045" ..........2
26 48736 50487361 Handle ...................................................1
27 Screw, cap, 5/16–18 x 1.25",
socket head ........................................12
28* Retaining ring, .750" .............................1
29* O-ring, 1.625 x 1.750 x .062"–70 ..........1
30 43699 50436996 Strap, trigger ......................................... 1
31 Screw, cap, #10–32 x .375",
button socket head ............................... 4
32 42576 50425760 Trigger ...................................................1
33 42547 50425471 Pivot, trigger .........................................1
34* Retaining ring ........................................ 2
35* O-ring, .437 x .562 x .062"–68 ..............1
36 43401 50434012 Washer, .75 x .50 x .03..........................1
37 42865 50428651 Spring, valve plunger ............................1
38* O-ring, .562 x .750 x .093"–68 ..............1
39 41095 50410952 Cap .......................................................1
40* Retaining ring, .750" .............................2
41 52063245 Spool .....................................................1
42 43556 50435566 Plug, spool ............................................ 1
43* O-ring, .250 x .375 x .062"–90 ..............1
44* Nut, 1/4–20, Hydra-Lok seal ................. 2
UPC No.
Key 78-3310- Part No. Description Qty
45 Plug, pipe, 1/8" NPTF ...........................2
46 30146 50301462 Pin, valve, .305 x .870" .........................1
47 40692 50406921 Spring, unloading valve ........................1
48 48261 50482610 Screw, set, 1/2–20, adjusting ................1
49* Washer, at, .514 x .030, copper ..........1
50 48260G 50482602 Cap, relief valve ....................................1
51 Screw, cap, 1/4–20 x 1.625, socket ......4
52 41432 50414323 Plug, port ..............................................2
53 49947 50499475 Decal ..................................................... 1
54 48734 50487345 Decal, OC/CC setting ...........................1
55 49946 50499467 Decal, warning ......................................1
56 41547 50415471 Decal, Greenlee ....................................1
57 54913 90549139 Washer, conical, .55 x .25 x .05 ............4
58 41873 50418730 Ball, steel, .5" ........................................ 1
59 49234 50492349 Stop, ball ...............................................1
60 41600 50416003 Retaining ring, .687 ............................... 1
61 55060 90550609 Screw, M12-1.75 x 12 mm set ..............1
62 03821 50038214 Spring ...................................................2
63 55063G 90550633 Pin, grooved, 3 mm...............................1
64 05317 50053175 Button, die release ................................ 1
65 05319 50053191 Pin, die release......................................1
66 05316 50053167 Pin, die release......................................1
67 05318 50053183 Button, die release ................................ 1
68 55064 90550641 Rollpin, 3 mm x 10 mm ......................... 1
69 55061 90550617 Screw, M5-.8 x 5 mm set ......................1
70 06214 50062140 Decal, pinch warning ............................1
72 49959 50499599 Decal, sound ......................................... 1
73* Backup ring ...........................................1
Repair Kit
* 49343G 50493434 Packing kit (includes items
marked with an asterisk) ....................... 1
Decals
49947 50499475 Decal, press/ow ..................................1
48734 50487345 Decal, OC/CC setting ...........................1
49946 50499467 Decal, warning ......................................1
41547 50415471 Decal, Greenlee ....................................1
06214 50062140 Decal, pinch warning ............................1
49959 50499599 Decal, sound ......................................... 1
Hydraulic Crimping Tools
Greenlee Tools, Inc. 4455 Boeing Dr. • Rockford, IL 61109-2988 USA • 815-397-7070
20
Illustration—
LPK1240
2
3
4
9
54
6
11
12
70
13
51
27
40
39
37
38
22
45
10
5
17
74
18
7
25
24
25
30
32
34
31
33
28
26
41, 42, 43
35
36
40
47
46
50
48
49
56
69
55
20
14
29
44
16
15
19
15
16
44
24
23
21
57
53
71
73
72
65
63
66
59
67
58
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61
62
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8
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Greenlee LPK1230, LPK1240, LPK1240K, LPK1550, LPK1550FT User manual

Greenlee
Brand
Greenlee
Model
LPK1230, LPK1240, LPK1240K, LPK1550, LPK1550FT
Category
Power tools
Type
User manual
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